Tapered isolating element for a ball bat and system for using same

ABSTRACT

A ball bat extending about a longitudinal axis. The bat includes a handle portion, a barrel portion and an injection molded element non-removably attached to the handle member. The barrel portion has a proximal region and a distal region spaced apart by a central region. The element has a tapered proximal region and barrel engaging region. The barrel engaging region of the element non-removably engages the proximal region of the barrel portion. The bat has a total length measured from a proximal end of the handle portion to a distal end of the barrel portion. The handle portion has a length that is less than 70 percent of the total length.

RELATED U.S. APPLICATION DATA

The present invention claims the benefit of the filing date under 35U.S.C. §119(e) of U.S. Provisional Patent Application Ser. No.61/756,089, filed on Jan. 24, 2013, which is hereby incorporated byreference in its entirety. The present application is related to U.S.patent application Ser. No. 14/041,481, now U.S. Pat. No. 9,242,156,Ser. Nos. 14/041,604, and 14/041,707 filed on the same day herewith, thefull disclosure of which is hereby incorporated by reference.

FIELD OF THE INVENTION

The present invention relates to an element for coupling a handleportion to a barrel portion of a ball bat, and a system and method ofcustomizing a ball bat.

BACKGROUND OF THE INVENTION

Baseball and softball bats are well known sporting goods. The materialsused to form bats have changed and become more varied overtime,including materials such as wood, aluminum, other alloys, fibercomposite materials and combinations thereof. Additionally, theconstruction of ball bats has also evolved and become more variedovertime. For example, many current ball bats are formed of separatehandle and barrel portions. In many instances, the incorporation of newmaterials and compositions for ball bats has led to increaseddurability, reliability and performance. The new materials andcompositions have also increased the number of bat configurations andchoices available to ball players. Still further, the number of baseballand/or softball organizations has also increased overtime. Such baseballand softball organizations periodically publish and update equipmentstandards and/or requirements including performance limitations for ballbats.

The current state of ball bats includes some drawbacks. The cost of manyexisting bat constructions can be very high due to the complexity of theconstruction, the cost of the materials, and the time required toproduce the finished ball bat. The wide variety of bat constructions andmaterials can make it difficult for bat retailers to know which bats tostock. Additionally, many bat models have long production lead times.Additionally, although bat construction and composition has evolved andbecome more varied overtime, many ball bats still provide excessiveshock and/or vibration to the player upon hitting a ball, particularlyon off-center impacts or impacts away from the sweet spot of the ballbat.

Accordingly several needs still exist in the ball bat industry. A needexists for bat configurations that provide exceptional performance,durability and reliability characteristics without excessive materialand/or manufacturing costs. What is needed is a bat construction thatoffers more design flexibility and exceptional performance in a costeffective and efficient manner. It would be desirable to provide a batconstruction and system that is cost effective, allows for customizationof the bat, short production lead times and exceptional performance. Aneed exists for a ball bat that provides exceptional feel to the player,even upon off center impacts with the ball. It would also beadvantageous to provide an efficient, easy to use tool, system or methodthat would allow a user to customize his or her bat and obtain a batthat matches that player's particular needs including design, skilllevel, performance and durability. It is also desirable to provide aball bat with a unique appealing appearance that looks great andperforms well.

SUMMARY OF THE INVENTION

The present invention provides a ball bat extending about a longitudinalaxis. The bat includes a handle portion, a barrel portion, and aninjection molded element non-removably attached to the handle member.The handle portion has a generally uniform outer diameter with respectto the longitudinal axis. The barrel portion has a proximal region and adistal region spaced apart by a central region. The element has atapered proximal region and barrel engaging region. The barrel engagingregion of the element non-removably engages the proximal region of thebarrel portion. The bat has a total length measured from a proximal endof the handle portion to a distal end of the barrel portion. The handleportion has a length that is less than 70 percent of the total length.

According to a principal aspect of a preferred form of the invention, aball bat extending along a longitudinal axis. The bat includes a handleportion, a barrel portion and an element coupled to the handle portion.The handle portion has a generally uniform outer diameter with respectto the longitudinal axis. The barrel portion has a proximal region and adistal region spaced apart by a central region. The element has atapered proximal region and barrel engaging region. The element furtherincludes a tubular wall that defines a longitudinal bore for receivingthe handle member, and an outer wall extending over at least a portionof the length of the element. The outer wall is spaced apart from thetubular wall by at least one rib. The barrel engaging region of theelement non-removably engages the proximal region of the barrel portion.The bat has a total length measured from a proximal end of the handleportion to a distal end of the barrel portion. The handle portion has alength that is less than 70 percent of the total length.

According to another preferred aspect of the invention, a ball batextends along a longitudinal axis and includes a handle portion, abarrel portion, an injected molded element non-removably attached to thehandle member, and a tubular insert. The handle portion has a generallyuniform outer diameter with respect to the longitudinal axis. The barrelportion has a proximal region and a distal region spaced apart by acentral region. The element includes a tubular inner wall defining alongitudinal bore. The element is non-removably attached to the handlemember, and includes a tapered proximal region, a barrel engagingregion, and an insert engaging region. The tubular insert is engagedwith the insert engaging region of the element. The insert engagingregion includes a stop for engaging the insert and inhibitinglongitudinal movement of the insert in a proximal direction. The barrelengaging region of the element non-removably engaging the proximalregion of the barrel portion. The bat has a total length measured from aproximal end of the handle portion to a distal end of the barrelportion, and the handle portion has a length that is less than 70percent of the total length.

According to another preferred aspect of the invention, a method forenabling a user to customize a ball bat using an electronic devicehaving a processor, a display operably coupled to the processor, aninput mechanism, and a memory operably coupled to the processor. Themethod includes the steps of presenting to the user on the display ofthe electronic device representations of a plurality of handle portionsof the ball bat. The plurality of handle portions vary from one anotheraccording to at least one handle portion characteristic. The handleportion characteristic can be length, outer diameter, weight, color,resistance to bending, strength, wall thickness, material, orcombinations thereof. The method further includes receiving user inputthrough the input mechanism selecting the one of the plurality of handleportions, and presenting to the user on the display of the electronicdevice representations of a plurality of barrel portions of the ballbat. Each of the barrel portions has an outer diameter and a length. Theplurality of barrel portions varies from one another according to atleast one barrel portion characteristic. The barrel portioncharacteristic can be length, weight, weight distribution, nominal outerdiameter, maximum outer diameter, wall thickness, strength, model name,color, stiffness, material, or combinations thereof. The method furtherincludes receiving user input through the input mechanism selecting theone of the plurality of barrel portions, and presenting to the user onthe display of the electronic device representations of a plurality ofelements. The element is configured to fixedly engage to the handleportion and to fixedly engage to the barrel portion. The plurality ofelements varies from one another according to at least one elementcharacteristic. The element characteristic can be length, weight, color,color pattern, texture, tactile feel, material, material hardness, andcombinations thereof. The method further includes the steps of receivinguser input through the input mechanism selecting the one of theplurality of elements, presenting a representation of the ball bat in anassembled state on the display with the selected handle portion, barrelportion and element included in the representation, and receiving userinput through the input mechanism confirming the selection of the handleportion, the barrel portion and the element.

According to another preferred aspect of the invention, a system forcustomizing a ball bat for a user includes a processor, a displayoperably coupled to the processor, an input mechanism, and a memoryoperably coupled to the processor. The ball bat includes a handleportion, a barrel portion and an element. The electronic device isconfigured to provide at least first, second third and fourth userinterfaces to the user. The first user interface includes arepresentation of at least one handle portion of the ball bat. The firstuser interface is configured to enable the user to select or vary atleast one handle portion characteristic. The handle portioncharacteristic can be length, outer diameter, weight, color, resistanceto bending, strength, wall thickness, material, or combinations thereof.The second user interface includes a representation of at least onebarrel portion of the ball bat. The second user interface is configuredto enable the user to select or vary at least one barrel portioncharacteristic of the barrel portion of the ball bat. The barrel portioncharacteristic can be length, weight, weight distribution, nominal outerdiameter, maximum outer diameter, wall thickness, strength, model name,color, stiffness, material, or combinations thereof. The third userinterface includes a representation of at least one element of the ballbat. The element is configured to fixedly engage to the handle portionand to fixedly engage to the barrel portion. The third user interface isconfigured to enable the user to select or vary at least one elementcharacteristic of the element of the ball bat. The elementcharacteristic can be length, weight, color, color pattern, texture,tactile feel, material, material hardness, or combinations thereof. Thefourth user interface includes a representation of the ball batincluding the handle portion, the barrel portion and the element. Theinput mechanism is configured to enable the user to confirm the selectedcombination of the handle portion, the barrel portion and the element.

This invention will become more fully understood from the followingdetailed description, taken in conjunction with the accompanyingdrawings described herein below, and wherein like reference numeralsrefer to like parts.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a ball bat in accordance with a preferredembodiment of the present invention.

FIG. 2 is a side perspective view of the coupling of a handle portionand a barrel portion of the bat in accordance with a preferredembodiment of the present invention.

FIG. 3 is a longitudinal cross-sectional view of the coupling of thehandle portion of the bat to the barrel portion of the ball bat of FIG.1.

FIG. 4 is a side perspective view of a tapered element of the ball batof FIG. 1.

FIG. 5 is another side perspective view of the tapered element of FIG.4.

FIG. 6 is a side view of the tapered element of FIG. 4.

FIG. 7 is a distal end view of the tapered element of FIG. 4.

FIG. 8a is a longitudinal cross-sectional view of the tapered element ofFIG. 4.

FIGS. 8b through 8c illustrate longitudinal cross-sectional views of atapered element of a ball bat in accordance with alternative preferredembodiments of the present invention.

FIG. 9 is longitudinal cross-sectional view of a tapered element of aball bat in accordance with another alternative preferred embodiment ofthe present invention.

FIG. 10 is a longitudinal cross-sectional view of a tapered element of aball bat in accordance with another alternative preferred embodiment ofthe present invention.

FIG. 11 is a distal end view of a tapered element of a ball bat inaccordance with another alternative preferred embodiment of the presentinvention.

FIG. 12 is a side perspective view of a tapered element in accordancewith an alternative preferred embodiment of the present invention.

FIG. 13 is a distal end perspective view of the element of FIG. 12.

FIG. 14 is a side view of the element of FIG. 12 and a longitudinalcross-sectional view of a portion of the barrel portion and an insert.

FIG. 15 illustrates a pultrusion method of forming a plurality of handleportions of a ball bat in accordance with an alternative preferredembodiment of the present invention.

FIG. 16 schematically illustrates a system for customizing and orderinga ball bat in accordance with an alternative preferred embodiment of thepresent invention.

FIGS. 17 through 25 illustrate examples of user interfaces forcustomizing a ball bat and components thereof in accordance with thesystem of FIG. 16.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, a ball bat is generally indicated at 10. The ballbat 10 of FIG. 1 is configured as a baseball bat; however, the inventioncan also be formed as a softball bat, a rubber ball bat, or other formof ball bat. The bat 10 includes a frame 12 extending along alongitudinal axis 14. The tubular frame 12 can be sized to meet theneeds of a specific player, a specific application, or any other relatedneed. The frame 12 can be sized in a variety of different weights,lengths and diameters to meet such needs. For example, the weight of theframe 12 can be formed within the range of 15 ounces to 36 ounces, thelength of the frame can be formed within the range of 24 to 36 inches,and the maximum diameter of the barrel portion 18 can range from 1.5 to3.5 inches.

The frame 12 has a relatively small diameter handle portion 16, arelatively larger diameter barrel portion 18 (also referred as a hittingor impact portion), and an intermediate tapered element 20. The handleand barrel portions 16 and 18 and the intermediate tapered element 20are formed as separate structures, which are connected or coupledtogether. This multi-piece frame construction enables each of the threecomponents to be formed of different materials or similar materials tomatch a particular player need or application.

Referring to FIGS. 1 and 3, the handle portion 16 is an elongate tubularstructure that extends along the axis 14 and has a proximal end region22 and a distal end region 24. Preferably, the handle portion 16 issized for gripping by the user and includes a grip 26, which is wrappedaround and extends longitudinally along the handle portion 16, and aknob 28 connected to the proximal end 22 of the handle portion 16. Thedistal end region 24 is coupled to the element 20. The handle portion 16is preferably a cylindrical structure having a uniform outer diameteralong its length. The handle portion 16 can also have a uniform innerdiameter along its length. In other implementations, the handle portioncan be formed with a non-uniform inner diameter, and/or a non-uniformouter diameter along its length. In other implementations, the handleportion can be a non-hollow elongate member. In other implementations,the handle portion may have a non-cylindrical shape. The handle portion16 is formed of a strong, generally flexible, lightweight material,preferably a fiber composite material. Alternatively, the handle portion16 can be formed of other materials such as an aluminum alloy, atitanium alloy, steel, other alloys, a thermoplastic material, athermoset material, wood or combinations thereof. In other alternativeembodiments, the handle can have slightly tapered or non-cylindricalshapes.

The barrel portion 18 of the frame 12 is “tubular,” “generally tubular,”or “substantially tubular,” each of these terms is intended to encompasssoftball style bats having a substantially cylindrical impact (or“barrel”) portion as well as baseball style bats having barrel portionswith generally frusto-conical characteristics in some locations.Alternatively, other hollow, tubular shapes can also be used. The barrelportion 18 extends along the axis 14 and has an inner surface 32 and anouter surface 34. The barrel portion 18 includes a proximal region 36, adistal region 38 spaced apart by a central region 40. The barrel portion18 is configured for impacting a ball (not shown), and preferably isformed of strong, durable and resilient material, such as, an aluminumalloy. In alternative preferred embodiments, the proximal member 36 canbe formed of one or more composite materials, a titanium alloy, ascandium alloy, steel, other alloys, a thermoplastic material, athermoset material, wood or combinations thereof.

As used herein, the terms “composite material” or “fiber compositematerial” refer to a plurality of fibers impregnated (or permeatedthroughout) with a resin. In one preferred embodiment, the fibers can besystematically aligned through the use of one or more creels, and drawnthrough a die with a resin to produce a pultrusion, as discussed furtherbelow. In an alternative preferred embodiment, the fibers can beco-axially aligned in sheets or layers, braided or weaved in sheets orlayers, and/or chopped and randomly dispersed in one or more layers. Thecomposite material may be formed of a single layer or multiple layerscomprising a matrix of fibers impregnated with resin. In particularlypreferred embodiments, the number layers can range from 3 to 8. In otherimplementations, more than 8 layers can be used. In multiple layerconstructions, the fibers can be aligned in different directions (orangles) with respect to the longitudinal axis 14 including 0 degrees, 90degrees and angular positions between 0 to 90 degrees, and/or in braidsor weaves from layer to layer. For composite materials formed in apultrusion process, the angles can range from 0 to 90 degrees. In someimplementations, the layers may be separated at least partially by oneor more scrims or veils. When used, the scrim or veil will generallyseparate two adjacent layers and inhibit resin flow between layersduring curing. Scrims or veils can also be used to reduce shear stressbetween layers of the composite material. The scrim or veils can beformed of glass, nylon or thermoplastic materials. In one particularembodiment, the scrim or veil can be used to enable sliding orindependent movement between layers of the composite material. Thefibers are formed of a high tensile strength material such as graphite.Alternatively, the fibers can be formed of other materials such as, forexample, glass, carbon, boron, basalt, carrot, Kevlar®, Spectra®,poly-para-phenylene-2,6-benzobisoxazole (PBO), hemp and combinationsthereof. In one set of preferred embodiments, the resin is preferably athermosetting resin such as epoxy or polyester resins. In other sets ofpreferred embodiments, the resin can be a thermoplastic resin. Thecomposite material is typically wrapped about a mandrel and/or acomparable structure (or drawn through a die in pultrusion), and curedunder heat and/or pressure. While curing, the resin is configured toflow and fully disperse and impregnate the matrix of fibers.

The bat 10 further includes an end cap 30 attached to the distal region38 of the barrel portion 18 to substantially enclose the distal region38. In one preferred embodiment, the end cap 30 is bonded to the distalregion 38 through an epoxy. Alternatively, the end cap can be coupled tothe distal region through other adhesives, chemical bonding, thermalbonding, an interference fit, other press-fit connections andcombinations thereof.

Referring to FIGS. 1 and 3 through 7, a preferred embodiment of theintermediate tapered element 20 is shown in greater detail. The element20 is a transitional member that connects the handle portion 16 to thebarrel portion 18. In one preferred embodiment, the element 20 includesa tapered proximal region 50 and a barrel engaging region 52. Inparticularly preferred embodiments, the barrel engaging region 52 canalso be tapered similar to the proximal region 50 such that the elementhas a frustoconical shape.

The element 20 can be formed of a single material, or two or moredifferent materials. In one preferred embodiment, the element 20includes a base layer 54 formed of a first material and an outer layer56 formed of a second material. The first and second materials arepreferably formed of lightweight, tough, durable materials, such asengineered thermoplastic polyurethane (ETPU). Alternatively, the firstand second materials can be formed of other materials, such asthermoplastic materials, thermoset materials, a composite material, afiber composite material, aluminum, an alloy, wood, and combinationsthereof. The first material preferably has a durometer value (hardnessvalue) within the range of 45 on the Shore D hardness scale to 150 onthe Shore R hardness scale. In a particularly preferred embodiment, thefirst material has a durometer value within the range of 100 to 140 onthe Shore R hardness scale. One important aspect of the presentinvention is that although the first material of the element 20 isformed of a hard material, the element 20 significantly reduces thelevel of undesirable vibrational and shock energy extending from thebarrel portion 18 to the handle portion 16 upon impact with a ball.

The second material preferably has a durometer value within the range of20 on the Shore A scale to 120 on the Shore R scale. In a particularlypreferred embodiment, when the element is formed with a second material,the second material has a durometer within the range of 20 to 90 on theShore A scale. The first and second materials can be different materialsor the same material but with different characteristics, such ashardness. The first material is preferably harder or has a Shoredurometer value that is greater than the second material. In analternative preferred embodiment, the first and second materials canhave the same or similar hardness values. In another alternativeembodiment, the second material can have a hardness value that isgreater than the first material.

Incorporation of the outer layer 56 provides additional designflexibility to the element. In embodiments where the second material ofthe outer layer 56 has a lower durometer value than the base layer 54,the outer layer 56 has a different feel when touched compared to thefeel of the base layer 54 or other components of the bat 10. The outerlayer 56 may be continuous and entirely cover the base layer 54, or theouter layer 56 can be formed into a variety of different shapes orpatterns with portions of the base layer 54 visible through one or moreopenings 58 defined in the outer layer 56. FIG. 1, FIG. 2 and FIGS. 4-6illustrate three separate examples of configurations of the outer layer56 wherein portions of the base layer 54 are visible through theopenings 58 in the outer layer 56. The three examples are representativesamples and are not intended to be limiting. The present inventioncontemplates the use of other designs, patterns, shapes, and graphicaland/or alphanumeric indicia. In one preferred embodiment, the outerlayer 56 can be configured to form graphical and/or alphanumeric indicia70 representative of a trademark (such as, for example, the DeMarini®“D” registered trademark), a service mark, a design, a logo, acertification mark, a warning, an instruction, other markings orcombinations thereof. The outer layer 56 is preferably slightly raisedwith respect to the base layer 54 such that the graphic, design orpattern taken by the outer layer 56 is more pronounced, threedimensional and visible. Additionally, the base layer 54 can be formedin one color or multiple colors, and the outer layer 56 can be formed ina different color, or a different combination of colors. In otherpreferred embodiments, the base layer 54 and the outer layer 56 can usethe same color or the same color combinations. The outer layer 56 canalso have a different texture than the base layer 54.

The element 20 is preferably an injection molded member produced in aninjection mold or in an operation using an injection molding apparatus.The injection molding apparatus can include an injection mold having amold cavity that defines the shape of the element 20 (or one half of theelement). In one preferred embodiment, the element 20 is injectionmolded over the handle portion 16. The handle portion 16 extends withinthe mold (and essentially forms part of the mold) and the first materialof the element 20 is injection molded about the handle portion. Theinjection molding of the element 20 over the handle portion 16 isreferred to as over-molding of the element 20 to the handle portion 16.The mold can be a split mold having two major sections. Thethermoplastic material can be injected into the mold cavity from aninjection molding extruder. The thermoplastic material can be suppliedthrough an inlet tube to the interior of the extruder, which is heatedto reduce the viscosity of the thermoplastic material and make itflowable. A piston or screw can be used to force the flowablethermoplastic material out of the extruder into a manifold system, whichcan be heated. The manifold system can include one, two, three or moreflow paths for routing the flowable thermoplastic material to injectionports. The locations of the injection ports are preferably spaced apartto enable the thermoplastic material to readily flow and fill the moldcavity in an efficient and timely manner. The injection of the flowablethermoplastic material can be performed in stages through the use of oneor more valves. One or more sensors, such as pressure and/or temperaturesensors, can be utilized with the mold to determine when the flowablethermoplastic material has reached selected locations within the moldcavity. When the flow of the thermoplastic material reaches apredetermined value, such as a predetermined pressure at one of thepressure sensors, the valve can reposition and reroute or redirect theflow of the thermoplastic material down a second flowpath through asecond injection port. In alternative preferred embodiments, other formsof injection mold apparatuses can be used. The type of mold, the numberof flow paths, the number of injections ports or gates, the number ofvalves, the configuration of the valves, the type of extruder or otherinjection mechanism, the configuration, pressure, temperature and orderof the flow and introduction of the thermoplastic material can bevaried. The injection molding apparatus described above is one exampleand is not intended to be limiting. One of skill in the art understandsthat a wide variety of injection molding apparatuses can be used toachieve the desired result from injection molding process or operation.

In one preferred embodiment, the distal end region 24 of the handleportion 16 can be inserted into the injection mold such that the element20 is injection molded around the distal end region 24. The distal endregion 24 of the handle portion 16 can be unfinished and roughened toenhance the bonding from the molding of the element 20 to the region 24.The over-molding of the element 20 to the distal end region 24 of thehandle region 16 produces an exceptional bond between the twocomponents. As the injection molded first material of element 20 curesit shrinks slightly and further increases the bond strength of theelement 20 to the handle portion 16. Accordingly, the element 20 isshrink-fit to the handle portion 16. Importantly, in the over-moldingprocess, no separate adhesive or additional fastener is required.Therefore, in a preferred embodiment, the element 20 is over-molded tothe handle portion 16 without the use of a separate adhesive or one ormore mechanical fasteners. The bonding and shrinkage of the firstmaterial of the element 20 to the handle portion 16 provides andexceptionally strong connection. Empirical testing of the bond of theelement 20 to the distal end region 24 found a resistance to separationof the element 20 molded to the handle portion 16, even when placedunder a 5000 lbf load.

In an alternative preferred embodiment, the element can be molded orinjection molded apart from the handle portion and attached to thehandle portion after it has been formed. In still other preferredembodiments, the element can be coupled to the handle portion by one ormore intermediate layers of material, adhesives, and/or fasteners.

When the element 20 is formed with a base layer 54 and an outer layer56, the outer layer 56 is preferably over-molded to the base layer 54.The base layer 54 is initially molded and allowed to cure. The baselayer 54 is then placed into a secondary mold where the outer layer 56is over-molded over the base layer 54. The over-molding operationprovides an exceptional bond between the base layer 54 and the outerlayer 56. The second material of the outer layer 56 flows and fills thesecondary mold about the base layer 54 to form the element 20. The firstand second materials may be hydroscopic to some degree. Therefore, it ispreferable for the over-molding of the outer layer 56 to the base layer54 to occur relatively soon after the base layer 54 has cured.

The distal ends of the element 20 and the handle portion 16 mayterminate at the same point along the axis 14. Alternatively, the distalend region 24 of the handle portion 16 may extend slightly further thanthe element 20, such that a small amount of the distal end region 24extends beyond the distal end of the element 20. In another alternativepreferred embodiment, the element 20 may extend slightly beyond thedistal end region 24 of the handle portion 16. In an alternativepreferred embodiment, the element 20 can be injection molded in twopieces, then placed about the distal end region 24 and molded to thedistal end region 24 under heat and pressure in a separate mold.

In alternative embodiments, the element 20 may be connected to thehandle portion 16 through chemical bonding, thermal bonding, one or morefasteners, an adhesive layer, an intermediate bonding layer, orcombinations thereof.

Referring to FIGS. 3 through 7, the element 20 defines a longitudinallyextending through-bore 60 for receiving the handle portion 16. Thebarrel engaging region 52 of the element 20 can include a tubular wall62 that also defines the bore 60, and an outer wall 64 that is spacedapart from the tubular wall 62 by at least one rib 66. The rib 66 canextend radially with respect to the axis 14 from the tubular wall 62 tothe outer wall 64. In a preferred embodiment, the tubular wall 62 andthe outer wall 64 define one or more cavities 72 between the ribs 66, orbetween the tubular wall 62 and the outer wall 64. The cavities 72preferably extend at least 40 percent of the length of the element 20.In alternative preferred embodiments, the cavities can extend over lessthan 40 percent of the length of the element 20 or more than 40 percentof the length of the element 20. In FIGS. 4 and 7, the element 20 isshown with eight ribs 66. In alternative preferred embodiments, thenumber of ribs 66 can be one, two, three, four, five or more.Preferably, the ribs 66 are evenly spaced or angled apart about theelement 20. The ribs 66 provide structural integrity to the element 20while allowing less material to be used, reduced weight and lowermaterial cost to produce the element 20.

Referring to FIGS. 4 through 6, the barrel engaging portion 52 of theelement 20 preferably has a generally tapered or frustoconical shape.The outer surface of the barrel engaging portion 52 preferably defines aplurality of recesses 68. The recesses 68 facilitate the engagement ofthe barrel engaging portion 52 to the proximal end region 36 of thebarrel portion 18 by allowing excess adhesive or other bonding agent toflow within the recess 68 and cure. The recesses 68 facilitate the flowof such adhesives, particularly fast curing adhesives, during theassembly process. The recesses 68 can provide for a more efficient,and/or varied bond line between the barrel engaging portion 52 of theelement 20 and the proximal end region 36 of the barrel portion 18. Inone particularly preferred embodiment, one or more locations of thebarrel engaging portion 52 between the recesses 68 may directly contactthe proximal end region 36 while the adhesive fills the recesses to bondthe element 20 to the proximal end region 36. Three recesses 68 areshown in the preferred embodiment of FIGS. 4 through 6. However, inalternate preferred embodiments, other numbers of recesses can be used.In other alternative preferred embodiments, the shape and/or size of therecesses can be varied into one or more different shapes, and/or thedepth of the recesses can be varied one or more different depth orvariable depths. In another alternative preferred embodiment, the barrelengaging portion can be formed with a plurality of projections tofacilitate the engagement of the element to the barrel portion. Inanother alternative preferred embodiment, the barrel engaging portioncan be formed with one or more recesses or without one or moreprojections.

Referring to FIGS. 1 through 3, the frustoconical shape of the barrelengaging region 52 of the element 20 diverges outwardly from the axis14. The frusto-conical shaped barrel engaging region 52 preferablytelescopically engages the proximal end region 36 of the barrel portion18. The proximal region 36 of the barrel portion 18 generally convergestoward the axis 14 to form a frusto-conical shape that is complementaryto the shape of the barrel engaging region 52 thereby providing atelescopic interlocking mechanical engagement. The engagement caninclude an adhesive.

The element 20 is preferably formed as a one piece integral structurethat connects the handle portion 16 to the barrel portion 18. Theelement 20 preferably completely isolates the barrel portion 18 from thehandle portion 16 such that no direct contact exists between the handleportion 16 and the barrel portion 18. The one-piece, integral structuremeans that once formed the element cannot be disassembled into two ormore pieces. The one-piece, integral structural cannot be separated intotwo or more pieces without essentially destroying the element 20. By wayof example, the knob 28 and end cap 30 of a ball bat are typically notintegral to the bat frame. The knob 28 and/or the end cap 30 can oftenbe removed without destroying either component. If two portions, partsor components of a bat can be separated by removing one or morefasteners, and/or by removing, dissolving or otherwise separating aseparate adhesive, the portions, parts or components do not form aone-piece, integral structure. The element 20 reduces unwanted shockand/or vibrational energy generated from impact of the barrel portion 18with a pitched ball from as it extends up and along the frame 12 to theuser's hands. The transition from the dissimilar materials of the barrelportion 18, the element 20 and the handle portion 16 further contributesto dampen or lessen the severity of the shock and/or vibrational energyfelt by the batter holding the handle portion 16 during or immediatelyfollowing impact with the ball. The engagement of the handle to theelement and the element to the barrel portion is preferably anon-threaded engagement.

Significantly, the element 20 of the present invention can be configuredto essentially decouple vibration and/or shock dampening from stiffness.Generally speaking, if one wished to reduce the shock and/or vibrationfelt by a batter upon hitting a ball, a soft, flexible, and/orelastomeric material would often be used to provide such dampening. Thesoft, flexible and/or elastomeric material would also have the effect ofreducing the overall stiffness of the bat. Accordingly, reducing theshock and/or vibration felt by a batter when hitting a bat is typicallyassociated with, or correlated to, a reduction in the stiffness of thebat. Importantly, the element 20 provides an additional level of designflexibility in that the element can be formed with a high level ofstiffness (or resistance to bending) and a high durometer (or a veryhard material) while also providing exceptional vibration and/or shockreduction. The decoupling of these stiffness to shock and/or vibrationdampening (or damping), and/or the decoupling of hardness to shockand/or vibration dampening are unique attributes provided byincorporation of the element 20 into the ball bat 10 and furtherincrease the design flexibility of a bat designer. The element 20 can beused to significantly reduce the vibration and/or shock energy felt by abatter when impacting a ball (especially off-center impacts) withoutreducing the stiffness of the ball bat or without reducing the hardnessof the element. In other embodiments, the element can be configured tobe softer and/or more flexible. The present invention provides a playeror bat designer with the ability to tailor, tune or customize a bat tomeet any need, application or player type.

The bat frame 12 formed of the handle portion 16, the barrel portion 18and the element 20 has a total length. The handle portion 16 has alength that less than 70 percent of the total length of the bat frame12. In other preferred embodiments, the length of the handle portion isless than 60 percent of the total length of the bat frame 12.

Referring to FIG. 8a , an alternative preferred embodiment of theintermediate tapered element 20 is illustrated. The element 20 includesthe proximal region 50 and the barrel engaging region 52. The tubularwall 62 defines the bore 60, and the outer wall 64 is spaced apart fromthe tubular wall 62 by a plurality of the ribs 66. The ribs 66 extendalong the entire barrel engaging region 52 and into the proximal region50 of the element 20 to define the cavities 72 that extend over at least70 percent of the length of the element 20. In an alternative preferredembodiment, the element can be configured such that the cavities extendover at least 60 percent of the length of the element.

Referring to FIG. 8b , the cavities 72 defined by the tubular wall 62,the outer wall 64 and the ribs 66 can be at least partially filled witha filling material 90. In one preferred embodiment, the filling material90 can be cellular material. In other preferred embodiments, the fillingmaterial 90 can be any material or combination of materials intended toalter one or more of the following characteristics of the element 20 andthe bat 10, such as the weight or weight distribution of the bat, theperceived swing weight of the bat, the sound produced by the bat or theelement upon impact with a ball, the vibration and/or shock dampeninglevel of the bat upon impact, and the durability of the element. Thefilling material 90 can be a urethane, an ETPU, a cellular foam, athermoplastic material, a thermoset material, a metal, wood, one or moreweight elements, or combinations thereof.

Referring to FIG. 8c , in another alternative preferred embodiment, oneor more of the ribs 66 may extend from one of the tubular wall 62 andthe outer wall 64 to the other of the tubular wall 62 and the outer wall64 without actually extending all the way to the other of the walls. Inthis manner, a gap 92 or space exists between the rib 66 and the outerwall 64 (or if the rib extends from the outer wall toward the tubularwall, then a space will exist between the rib and the tubular wall)thereby making adjacent cavities 72 continuous or a single cavity. Theradial size of the gap 92 can be generally constant along thelongitudinal length of the element. In one particularly preferredembodiment, the gap 92 (measured radially from the longitudinal axisbetween the rib and the outer wall (or the tubular wall) is within therange of 0.005 to 0.100 inch. In other alternative preferred embodiment,the gap may have other dimensions less than 0.005 inch or greater than0.100 inch. The gap 92 may allow for greater flexing or flexibility, orcontrolled or stepped flexibility, of the element 20 during use. The gap92 can also be employed to alter the feel, sound, weight, vibrationdampening level or other characteristic of the element 20 or the bat 10as a whole. In other preferred embodiments, the radial size of the gap92 can become smaller or larger as at it extends along the longitudinalaxis 14.

Referring to FIG. 9, in another alternative preferred embodiment, theelement 20 can be formed without ribs and without cavities. Accordingly,the element 20 can be one continuous piece of material, such as acontinuous base layer 54. In one particularly preferred embodiment, theelement is continuous without any cavities or enlarged openings. Inanother alternative preferred embodiment, the element 20 can be formedof continuous material comprised of the base layer 54 and theover-molded outer layer 56.

Referring to FIG. 10, in another alternative preferred embodiment, theelement 20 can be formed a cellular material, and without ribs orcavities. The cellular material can be open cell material or closed cellmaterial. The median size of the cells can also be varied depending uponthe desired characteristics of the element 20. In another alternativepreferred embodiment, the element formed of a cellular material can alsobe formed with at least one rib and a plurality of cavities.

Referring to FIG. 11, alternative preferred embodiments of the rib ofthe element are illustrated. In particular, a variety of differentshaped ribs 66 are illustrated. The ribs 66 can be generally planar andcan generally extend radially from the tubular wall 62 to the outer wall64 as illustrated in the embodiment of FIGS. 4 and 7. In alternativepreferred embodiments, the ribs 66 a can extend at angle α with respectto a plane 78 extending through and along the axis 14. The angle α canrange from plus or minus 1 to 90 degrees from the plane 78. In oneimplementation, the angle α can range from plus or minus 1 to 45 degreesfrom the plane 78. Although only three ribs 66 a are illustrated, it isunderstood that the element 20 can be formed with any number of the ribs66 a alone or in combination with one or more of the other shaped ribs.Other configurations for the ribs 66 are also illustrated. The rib 66 bis curved at it extends from the tubular wall 62 to the outer wall 64.The rib 66 c separates as it extends from the tubular wall 62 to theouter wall 64. The ribs 66 d and 66 e vary in thickness as they extendfrom the wall 62 to the wall 64. The rib 66 f extends at a sharp anglefrom the tubular wall 62 to the outer wall 64. The rib 66 h extends fromthe tubular wall 62 to the outer wall 64 in an ovular or circular shape.The present invention contemplates one or more of the illustrated ribs,or combinations of the illustrated ribs, to be used in the element. Inother alternative embodiments, the one or more ribs may spirally extendalong the element. In other alternative embodiments, the ribs may form alattice structure. In still other alternative embodiments, the ribs mayform other geometric or curved shapes.

Referring to FIGS. 12 through 14, another alternative preferredembodiment of the present invention is illustrated. The element 20 canbe formed with an insert engaging portion 300 for engaging a proximalend region 302 of an insert 304. The tapered proximal region 50 and thebarrel engaging region 52 of the element 20 of the embodiment of FIGS.12 and 14 can be substantially similar to the tapered proximal region 50and the barrel engaging region 52 of the previously describedembodiments. The insert engaging portion 300 can be configured forengaging the insert 304 in a manner that securely positions the insertin a location such that at least a portion of the insert 304 isseparated from the barrel portion 18 by a desired or predeterminedamount.

The insert 304 is a tubular body that can have a consistent inner andouter diameter or can be formed with some amount of taper or curvaturealong its length such that the insert is cylindrical or substantiallycylindrical. The insert can be formed of one or more of the materialsused to form the barrel portion 18, as described above. The insertincludes a proximal end region 302 and a distal end region. Over atleast a portion of the length of the insert 304, the insert 304 ispreferably visibly spaced apart from the inner surface 32 of the barrelportion 18. The separation of the insert 304 and the barrel portion 18is preferably sized to be within the range of 0.005 to 0.125 in (whenmeasured radially from the longitudinal axis 14 to the outer surface 34of the barrel portion 18) such that the insert 304 is sufficientlyseparated from the inner surface of the barrel portion 18 to allow forindependent movement between the two elements, while still allowing foroperable engagement of the barrel portion 18 and the insert 304 uponimpact with a ball. In another preferred embodiment, the separation ofthe insert 304 and the barrel portion 18 can be just sufficient enoughto allow for independent movement of the insert 304 relative to thebarrel portion 18 upon impact with a ball. Independent movement betweenthe insert 304 and the barrel portion 18 may exist even if theseparation is not visible to the naked eye.

In one particularly preferred embodiment, at least one of the ribs 66and the tubular wall 62 can longitudinally extend from the barrelengaging portion 52 to form the insert engaging portion 300. In theembodiment of FIGS. 12 through 14, all eight of the ribs 66 are shownextending from the barrel engaging portion 52 of the element 20. Inalternative preferred embodiments, other numbers of ribs can also beused. In one particularly preferred embodiment, at least three radiallyspaced apart ribs extend from the barrel engaging portion 52 to provideat least three lines or points of contact for supporting the tubularinsert 304.

Each rib 66 may include a shoulder 306 for engaging the proximal end 308of the insert 304. The shoulder 306 enables the rib 66 to provide a stop310 that limits the longitudinal movement of the insert 304 in aproximal direction, and an insert bearing surface 312 for supporting aportion of the inner surface of the proximal end region 302 of theinsert 304. The insert engaging portion 300 provides a secure supportfor the proximal end region 302 of the insert 304. The insert engagingportion 300 is another important feature or function that can beincorporated into and supplied by the element 20. The insert engagingportion 300 further increases the versatility and customizationpossibilities available to the bat designer or user. The element 20entirely isolates and separates the insert 304 and the barrel portion 18from contact with the handle portion 16 thereby further enhancingreduction of undesirable vibrational and/or shock energy extending alongthe bat from the barrel portion to the handle portion in response toimpact with a ball. The handle portion 16 is free of contact with thebarrel portion 18 and free of contact with the insert 304.

In another alternative preferred embodiment, the insert engaging portion300 can be incorporated into the barrel engaging portion of the element.In yet another alternative preferred embodiment, the insert engagingportion may include a ring, a band or other tubular form of bearingsupport for supporting the inner surface of the insert. The tubularbearing support can have a uniform diameter along its length or includea taper or frustoconical shape. In another alternative preferredembodiment, the tubular bearing support can include a continuousshoulder and a continuous insert bearing surface (similar to theshoulder 306 and bearing surface 312, but continuous and not spacedapart as shown in FIGS. 12 through 14)

Referring to FIG. 15, in one preferred embodiment, the handle portion 16is formed from a pultrusion process. FIG. 15 illustrates one pultrusionprocess arrangement. One of skill in the art would understand that otherarrangements of pultrusion process components can be used to producepultruded components, such as handle portions, barrel portions orinserts of ball bats. The present invention contemplates the use of allexisting arrangements of pultrusion processes for producing fiberreinforced thermoplastic or fiber composite ball bat components.

Pultrusion is one of the most cost effective methods of producing highquality fiber reinforced thermoplastic materials or fiber compositematerials. Pultrusion is similar to extrusion but differs in thatextrusion relies on a press to push unreinforced thermoplastic materialsthrough a short die. Pultrusion involves pulling a variety of reinforcedfibers, wetted by one or more thermosetting or thermoplastic resinsthrough a heated die to produce a continuous article, such as acylindrical handle portion. Polymerization of the resin occurs as thewetted fibers pass through the heated die to cure the resin and form acontinuous rigid structure. Pultrusion is ideal for producing fiberreinforced thermoplastic or fiber composite materials. It is acontinuous process that produces very little waste. The fibers canextend along the longitudinal axis of the cylindrical article or beapplied, or pulled from an angle with respect to the longitudinal axisand wound around to produce a number of different angled fiberconfigurations. The fibers can also be pulled through the pultrusionprocess as part of a woven fabric (a braided fabric or a tubular socklike fabric) thereby enabling the pultruded component to have somefibers that extend at a 90 degree angle with respect to the longitudinalaxis 14. The pultrusion process can result in a continuous cylindricalbody extending that then can be cut into desired lengths. Numerousprocess variables such as pull speed, die temperature, quality offiber/resin wet-out, and fiber volume can affect the quality ofpultruded composites.

A pultruded composite material can consist of reinforcing materials,such as unidirectional fibers (or rovings), continuous fiberglass matand a thermoset resin that binds the composite together. A polyestersurfacing veil to improve the external appearance of the composite, andchemical resistance or weather-ability may also be added. A variety ofancillary materials may be added to the resin formulation, such aspigment for color, accelerators to speed the curing of the thermosetresin, internal release agents, and several various types of inertfillers, each having its own functionality. A pultruded profile can beuniquely designed to meet a custom application. An in-line winder can becombined with the pultrusion process to add filament winding capabilitywhich allows for increase bi-axial strength.

One preferred embodiment of a pultrusion process for making a handleportion 16 is illustrated as item 100 in FIG. 15. A plurality of fibers102 are fed from one or more creels 104 into a guide 106. One or more ofthe fibers 102 may be wound around one or more of the other fibers 102using an inline winder 108. The inline winder 108 provides for fibersextending through the pultruded product (the handle portion 16) in anon-zero fiber position. The angle of the fibers applied from the inlinewinder 108 can vary from 1 degree to 89 degrees. More preferably, theangle of the fibers applied from the inline winder can vary from 5degrees to 45 degrees. The winder increases the biaxial strength of thepultruded component. The assembly of fibers 110 is then fed through aresin bath 112. The resin bath 112 impregnates (or coats and surrounds)the assembly of fibers 110 with a thermosetting or thermoplastic resin.The resin bath 112 can be an open bath system or an injected die system.Upon exiting the resin bath 112, the wetted fiber assembly 110 can beformed in one or more performers 114. The performer 114 is configured tofacilitate the orientation of the fibers 110 prior to entry into aheated die 116. The heated die shapes the wetted fibers into the desiredconfiguration and controls the curing of the shaped assembly of wettedfibers. A pulling device 118 pulls the assembly of fibers 110 throughthe process. The pulling device 118 can consist of a pair ofreciprocating clamp pullers, or continuous pullers, such as a pair ofcontinuous belts containing pads for engaging the wetted fiber assembly.The pullers can be synchronized for a continuous pull at the desiredspeed typically ranging from 6 inches per minute to 14 feet per minute.In other embodiments, the pulling device 118 can be configured toprovide an intermittent pull. The pultruded product is then typicallycut at a predetermined desired length by a cut-off saw 120. Thepultrusion process 100 can be used to produce high quality fibercomposite handle portions 16 with the desired characteristics such asresistance to longitudinal bending, weight, strength, etc. Thepultrusion process 100 can also be used to produce barrel portions orbarrel inserts that have substantially uniform diameters over theirlength.

Referring to FIGS. 16 through 25, a system and method of customizing aball bat for a particular player, team, application, or league areillustrated. Various aspects of the present invention may be implementedusing a programmable computing device or a computer executing softwareinstructions. FIG. 16 shows an example of a system 200 for customizing aball bat. The system 200 is intended to be a representative example. Oneof skill in the art would understand that other arrangements ofelectronic components and communication links can be employed forimplementing the system 200. An electronic device 202, such as acomputer, smart phone, tablet, a personal data assistant, a digitalmusic player (IPOD etc) or a tablet, includes a processor 204, a systemmemory 206, a display 208, input device 210, a system bus 212 couplingthe components together, and an device interface 214. In one preferredembodiment, the display 208 can be a touch screen and also serve as theinput device 210.

The processor 204 comprises one or more processing units configured tocarry out instructions contained in one or more instruction modules ofthe memory 206. For purposes of this application, the term “processingunit” shall mean a presently developed or future developed processingunit that executes sequences of instructions contained in a memory.Execution of the sequences of instructions causes the processing unit toperform steps such as generating control signals. The instructions maybe loaded in a random access memory (RAM) for execution by theprocessing unit from a read only memory (ROM), a mass storage device, orsome other persistent storage. In other embodiments, hard wiredcircuitry may be used in place of or in combination with softwareinstructions to implement the functions described. For example, thememory 206 may be embodied as part of one or more application-specificintegrated circuits (ASICs). Unless otherwise specifically noted, thecontroller is not limited to any specific combination of hardwarecircuitry and software, or to any particular source for the instructionsexecuted by the processing unit.

The memory 206 comprises a persistent storage device or non-transientcomputer-readable medium storing data and code. The system memory 206may include ROM and RAM, a mass storage device, and/or some otherpersistent storage. The input devices 210 employed by the computer 202may be a keyboard, a joystick, a mouse, a keypad, a touch screen, avoice activated input and other related input devices.

The device interface 214 may be any type of interface used to obtainand/or send data from and/or to another device. For example, the deviceinterface 214 may be a conventional connector/port type interface, suchas universal serial bus (USB) interface, a Firewire/IEEE 1394 interface,a PS/2 interface, a PC/AT interface, an RS-232 interface, a serial portinterface, or an Ethernet port or other telephone-type interface. Stillfurther, the device interface 214 may include a wireless transceiver forwireless communication with another device. For example, the deviceinterface 214 may be implemented with a radio frequency transceiver,such as a WiFi or Bluetooth wireless transceiver. The device interface214 may alternately be implemented with an infrared frequencytransceiver, a light frequency transceiver, or an ultrasonic frequencytransceiver. The device interface 214 may be an internal interface, orit may alternately be an external network interface as is well known inthe art. Of course, it will be appreciated that other means ofestablishing a communications link with other computers may be used.Also, with various examples of the invention, the computer 202 may havea plurality of device interfaces 214.

Typically, the computer 202 will be configured to access one more othercomputing devices. The computer 202 will normally be capable ofoperating in a networked environment using logical connections to one ormore remote devices, such as other computers 222. The computer 202 maybe connectable to one or more remote devices through a local areanetwork (LAN) or a wide area network (WAN), such as the Internet 220.The remote computer 222 may include similar components as the computer202 including a processor 224, a memory 226, a display 228, an inputdevice 230, a bus 232 and a device interface 234. When used in anetworking environment, the computer system 202 may be connected to thenetwork through the device interface 214.

Referring to FIGS. 17 through 25, the computer 202 will execute softwareinstructions to implement various embodiments of the invention. Basedupon these instructions, the computer 202 will display a series of agraphical user interfaces to a user. The user will then manipulate oneor more input devices 210 to input data to the computer 202 through theuser interface (display) 208. For example, with various implementationsof the invention, a user will manipulate an input device 210, such as apointing device like a mouse, roller ball, joystick or touchpad, tochange the appearance of a selection indicator imbedded in the graphicaluser interface. The user input 210 is used to select a characteristic,feature, option or selection presented to the user on a particulargraphical user interface.

FIGS. 16 through 25 illustrate an example of the bat customization tool,system or method 200 for configuring, designing, specifying, selectingor ordering a customized ball bat. The display 208 displays a series ofcustomized user interfaces, UIs, (FIGS. 16 through 24), including avisual display of various options available for selection and/orcustomization by the user. By using the input device 210, such as amouse, touchpad or keyboard, a user can input information forcustomization of the ball bat into the computer 202. A user can make aninput selection by selecting one or more features, characteristics oroptions of the customized ball bat. The UIs can include otherinformation such as the name of the manufacturer, characteristics ofvarious bat models or bat components, other marketing materials, helpfulhints, design tips, selections of designs, fonts, graphics and stylesfor review by the user.

In response, the computer 202 receives the selection information canprocess or organize or relay the input information to the display 208,store it in the memory 206 or transmit the information to a locationapart or remote from the computer 202, such as via the internet 220 toone or more other electronic devices 222. The device interface 214 cantransfer the selection information or process selection information to aretailer, manufacturer or supplier of the customized bat for processing.

If the information is being provided to a retailer, for example theretailer can review its stock and select the bat components having thefeature characteristics specified by the user. If the information isbeing provided to a manufacturer or supplier, the manufacturer orsupplier may employ the selection information to manufacture a new ballbat or ball bat component that has the feature characteristics specifiedby the user. With some examples of the invention, the user's inputselection data may be continuously provided a retailer, supplier ormanufacturer. Alternately, the user's input selection data may beprovided to a retailer, supplier or manufacturer after the user hasindicated that the input selection data represents a final set ofordering info′ nation. For example, system 200 may postpone providingthe user's selection information to a retailer or manufacturer untilafter the user also has provided purchasing information, such as acredit card account information or electronic payment service accountinformation.

Referring to FIG. 17, a user interface UI 240 is illustrated. UI 240provides a plurality of windows configured to obtain information aboutthe intended user of the customized bat or the application for thecustomized bat. The GUI 240 can provide prompts, windows or selectionoptions 242 for determining the user's age, height, weight, and/or sex,the league or organization the bat will be used in, the user's skilllevel, any applicable player goal, the user's budget, and combinationsthereof. The UI 240 can also include one or more data fields 244 forallowing a user to enter alphanumeric data (e.g., the user's nickname)onto particular locations of the customized bat. UI 240 is onerepresentation of how this type of information can be inputted into thebat customization system. Other configurations of UI 240 can also beused.

Referring to FIG. 18, a user interface UI 246 is illustrated. Aplurality of handle portions 16 is illustrated. The UI 246 may alsoinclude one or more windows providing variations of a characteristic ofthe handle portions 16. The characteristic can be length, outerdiameter, weight, color, resistance to bending, material, andcombinations thereof. The input device 210 can be used to make aselection or otherwise navigate through the UI 246. GUI 246 is onerepresentation of a UI for allowing a user to select a handle portionthat is best for his or her needs, skill level, league, size, age,strength, etc. Other representations of the UI 246 can also be used. Inanother implementation, a single handle portion 16 can be illustrated,and one or more of the characteristics of the handle portion 16 can bevaried based upon input from the user through the input device 210. Forexample, the handle portion 16 may be shown in a first color, a firstlength and a first diameter. The user can select or input through theinput device 210 one or more different colors, a different length,and/or a different diameter.

Referring to FIG. 19, a user interface UI 248 is illustrated. Aplurality of barrel portions 18 is illustrated. The UI 248 may alsoinclude one or more windows providing variations of a characteristic ofthe barrel portions 18. The characteristic can be length, outerdiameter, weight, weight distribution, nominal outer diameter, maximumouter diameter, model name, color, stiffness, material, and combinationsthereof. The input device 210 can be used to make a selection orotherwise navigate through the UI 248. UI 248 is one representation of aUI for allowing a user to select a barrel portion that is best for hisor her needs, skill level, league, size, age, strength, etc. Otherrepresentations of the UI 248 can also be used. In anotherimplementation, a single barrel portion 18 can be illustrated, and oneor more of the characteristics of the barrel portion 18 can be variedbased upon input from the user through the input device 210. Forexample, the barrel portion 18 may be shown in a first color, a firstlength and a first diameter. The user can select or input through theinput device 210 one or more different colors, a different length,and/or a different diameter.

Referring to FIG. 20, a user interface UI 250 illustrating a pluralityof intermediate tapered elements 20 are provided. The UI 250 may alsoinclude one or more windows providing variations of a characteristic ofthe elements 20. The characteristic can be length, weight, model name,color, shape, texture, pattern, material, and combinations thereof. Theinput device 210 can be used to make a selection or otherwise navigatethrough the UI 250. UI 250 is one representation of a UI for allowing auser to select an element that is best for his or her needs, skilllevel, league, size, age, strength, etc. Other representations of the UI250 can also be used. In another implementation, a single element 20 canbe illustrated, and one or more of the characteristics of the element 20can be varied based upon input from the user through the input device210. For example, the element 20 may be shown in a first color and afirst length. The user can select or input through the input device 210one or more different colors and/or a different length.

Referring to FIGS. 21 and 22, user interfaces UIs 252 and 254illustrating a plurality of end caps 30 and knobs 28 are provided. TheUIs 252 and 252 may also include one or more windows providingvariations of a characteristic of the end caps 30 and the knobs 28,respectively. The characteristic can be weight, model name, color,shape, texture, pattern, design, material, and combinations thereof. Theinput device 210 can be used to make a selection or otherwise navigatethrough the UI 252 or the UI 254. UIs 252 and 254 are one set ofrepresentations of a UI for allowing a user to select an end cap 30 or aknob 28 that is best for his or her needs, skill level, league, size,age, strength, etc. Other representations of the UI 252 or the UI 254can also be used. In another implementation, a single end cap 30 and/ora single knob 28 can be illustrated, and one or more of thecharacteristics of the end cap 30 and/or the knob 28 can be varied basedupon input from the user through the input device 210. For example, theend cap 30 and/or the knob 28 may be shown in a first color and a firstsize. The user can select or input through the input device 210 one ormore different colors and/or a different size.

Referring to FIG. 23, a user interface UI 256 illustrating a pluralityof grips 26 are provided. The UI 256 may also include one or morewindows providing variations of a characteristic of the grips 26. Thecharacteristic can be length, color, thickness, texture, pattern,material, and combinations thereof. The input device 210 can be used tomake a selection or otherwise navigate through the UI 256. UI 256 is onerepresentation of a UI for allowing a user to select an element that isbest for his or her needs, skill level, league, size, age, strength,etc. Other representations of the UI 256 can also be used. In anotherimplementation, a single grip 26 can be illustrated, and one or more ofthe characteristics of the grip 26 can be varied based upon input fromthe user through the input device 210. For example, the grip 26 may beshown in a first color and a first texture. The user can select or inputthrough the input device 210 one or more different colors and/or adifferent texture.

Referring to FIG. 24, a user interface UI 258 is illustrated. Aplurality of tubular inserts 82 is illustrated. The UI 258 may alsoinclude one or more windows providing variations of a characteristic ofthe tubular insert 82. The characteristic can be length, outer diameter,weight, weight distribution, outer diameter, model name, stiffness,material, and combinations thereof. The input device 210 can be used tomake a selection or otherwise navigate through the UI 258. UI 258 is onerepresentation of a UI for allowing a user to select a tubular insertthat is best for his or her needs, skill level, league, size, age,strength, etc. Other representations of the UI 258 can also be used.

Referring to FIG. 25, a UI 260 can be configured to illustrate theassembled bat 10 in accordance with the user's inputted selections. TheUI 260 can also provide the user with the ability to edit, accept orcancel the selection. For example, different colors, color combinations,graphics styles, indicia, such as name 262, model names, etc. can beused, adjusted or edited by the user. Exploded views, zoom features orother component views may be available in the UI 260 to facilitatevisualization of the selected customized ball bat. The UI 260 enablesthe user to input one or more graphical and/or alphanumeric indicia ontoone or more of the ball bat components. For example, the player's nameor the player's team name may be uploaded to the system 200 forpresentation onto UI 260 or one of the other UIs. The user can thenadjust the size, position, color, colors, font, style, and otherparameter on the UI 260. The user can input a selection of a particularorientation, color, style of the indicia, remove the indicia, orcontinue to edit the indicia.

The UIs 246 through 260 can be arranged in different order, differentstyles or in different combinations. In one implementation, therepresentations of the bat components can be shown building one uponanother. For example, the UI 248 may be presented first to the userenabling the barrel portion 18 to be selected, followed by UI 258selecting an insert, followed by the UI 246 and UI 250. In such animplementation, the UI can illustrate the bat 10 being assembledcomponent by component on the display. The UIs can be arranged in anyorder, or combined in any combination.

The bat 10 of the present invention provides numerous advantages overexisting ball bats. One such advantage is that the bat 10 of the presentinvention is configured for competitive, organized baseball or softball.For example, embodiments of ball bats built in accordance with thepresent invention can fully meet the bat standards and/or requirementsof one or more of the following baseball and softball organizations:Amateur Softball Association of America (“ASA”) Bat Testing andCertification Program Requirements (including the current ASA 2004 BatStandard and the ASA 2000 Bat Standard); United States Specialty SportsAssociation (“USSSA”) Bat Performance Standards for baseball andsoftball; International Softball Federation (“ISF”) Bat CertificationStandards; National Softball Association (“NSA”) Bat Standards;Independent Softball Association (“ISA”) Bat Requirements; Ball ExitSpeed Ratio (“BESR”) Certification Requirements and other requirementsof the National Federation of State High School Associations (“NFHS”);Little League Baseball Bat Equipment Evaluation Requirements; PONYBaseball/Softball Bat Requirements; Babe Ruth League Baseball BatRequirements; American Amateur Baseball Congress (“AABC”) Baseball BatRequirements; and, especially, the NCAA BBCOR Standard or Protocol.Accordingly, the term “bat configured for organized, competitive play”refers to a bat that fully meets the ball bat standards and/orrequirements of, and is fully functional for play in, one or more of theabove listed organizations.

Further, bats produced in accordance with the present invention can beconfigured and customized to fully satisfy the particular needs of aparticular user, while providing players with a bat that is reliable,playable, produces exceptional feel and optimizes performance along thebarrel portion or hitting portion of the bat. Bats built in accordancewith the present invention provide the player with exceptional feel andperformance because the element isolates the barrel portion (and ifapplicable, the insert) from the handle portion of the bat therebysignificantly reducing (or reducing as desired by the player or batdesigner) the amount of vibrational and/or shock energy reaching theplayer through the handle portion upon impact with a ball. Batsconfigured in accordance with the present invention are cost effective,can be produced quicker with shorter lead times, less waste, and usingfewer man-hours. The present invention significantly improves theflexibility of the bat design further increasing the ability of the batto be specifically tailored, tuned and designed for a particular player,a particular team, and/or a particular application. The presentinvention can be used by retailers of all types, including on-lineretailers, to provide custom, made-to-order ball bats in an efficientand cost-effective manner. The present invention will enable manysuppliers to store or acquire bat components and not completed bats,thereby making ball bat stocking more efficient, resulting in fewerunused or close-out bat models.

While the preferred embodiments of the invention have been illustratedand described, it will be appreciated that various changes can be madetherein without departing from the spirit and scope of the invention.One of skill in the art will understand that the invention may also bepracticed without many of the details described above. Accordingly, itwill be intended to include all such alternatives, modifications andvariations set forth within the spirit and scope of the appended claims.Further, some well-known structures or functions may not be shown ordescribed in detail because such structures or functions would be knownto one skilled in the art. Unless a term is specifically and overtlydefined in this specification, the terminology used in the presentspecification is intended to be interpreted in its broadest reasonablemanner, even though may be used conjunction with the description ofcertain specific embodiments of the present invention.

What is claimed is:
 1. A ball bat extending along a longitudinal axis,the bat comprising: a handle portion having a proximal gripping regionand a distal region, and a uniform outer diameter with respect to thelongitudinal axis; a barrel portion having a proximal region and adistal region spaced apart by a central region, the distal region of thehandle portion not extending to the distal region of the barrel portionsuch that the distal region of the barrel portion does not overlap thedistal region of the handle portion; an element formed of athermoplastic or thermoset material and non-removably attached to thedistal region of the handle member, the element having a taperedproximal region, a barrel engaging region and including a tubular walland an outer wall, the barrel engaging region of the elementnon-removably engaging and being overlapped by the proximal region ofthe barrel portion, the barrel engaging region and the proximal regionof the element each having a maximum outer diameter, the maximum outerdiameter of the barrel engaging region being greater than the maximumouter diameter of the proximal region of the element, the proximalregion of the element having an exposed outer surface including a firsttexture and the barrel engaging region having an outer surface defininga second texture that is different from the first texture, the bathaving a total length measured from a proximal end of the handle portionto a distal end of the barrel portion, the tubular wall of the elementdefining a longitudinally extending bore, the handle portion extendingwithin the length of the bore such that at least a portion of thetubular wall of the element overlaps and engages a portion of the handleportion, the handle portion having a length that is less than 70 percentof the total length.
 2. The ball bat of claim 1, wherein the element isover-molded to the handle member.
 3. The ball bat of claim 1, whereinthe barrel engaging region of the element is tapered, and wherein theelement has a generally frustoconical shape.
 4. The ball bat of claim 3,wherein the proximal region of the barrel portion generally convergestoward the longitudinal axis to form a frustoconical shape that iscomplementary to and telescopically engages the barrel engaging regionof the element.
 5. The ball bat of claim 3, wherein an outer surface ofthe barrel engaging region of the element defines at least one recess.6. The ball bat of claim 1, wherein the barrel engaging region of theelement non-threadedly engages the proximal region of the barrelportion.
 7. The ball bat of claim 1, wherein the element is formed witha one-piece, integral structure without one or more cavities.
 8. Theball bat of claim 7, wherein the element is formed of one or more solidmaterials from the bore to the outer surface.
 9. The ball bat of claim1, wherein the element is formed of a material selected from groupconsisting of one or more solid materials, one or more cellularmaterials, and combinations thereof.
 10. A ball bat extending along alongitudinal axis, the bat comprising: a handle portion having a uniformouter diameter with respect to the longitudinal axis; a barrel portionhaving a proximal region and a distal region spaced apart by a centralregion; an element formed of at least first and second thermoplastic orthermoset materials and non-removably attached to the handle member, theelement having a tapered proximal region, a barrel engaging region andincluding a tubular wall and an outer wall, the barrel engaging regionof the element non-removably engaging and being overlapped by theproximal region of the barrel portion and not overlapped by the centralregion or the distal region of the barrel portion, the barrel engagingregion and the proximal region each having a maximum outer diameter, themaximum outer diameter of the barrel engaging region being greater thanthe maximum outer diameter of the proximal region, the bat having atotal length measured from a proximal end of the handle portion to adistal end of the barrel portion, the tubular wall of the elementdefining a longitudinally extending bore, the handle portion extendingwithin the bore such that at least a portion of the tubular wall of theelement overlaps and engages a portion of the handle portion, the handleportion having a length that is less than 70 percent of the totallength, the element including at least one base layer formed of at leastthe first thermoplastic or thermoset material, and an outer layer formedof the second thermoplastic or thermoset material.
 11. The ball bat ofclaim 10, wherein when the hardness of the first material is greaterthan the hardness of the second material, wherein the hardness ismeasured on a Shore hardness scale.
 12. The ball bat of claim 10,wherein the first and second materials are formed of different colors.13. The ball bat of claim 10, wherein the texture of the outer layer isdifferent than the texture of the outer surface of the base material.14. The ball bat of claim 10, wherein the outer layer is over-molded tothe at least one base layer.
 15. The ball bat of claim 10, wherein theouter layer includes one or more openings enabling at least a portion ofthe base layer to be visible on the outer surface of the element. 16.The ball bat of claim 10, wherein the tapered proximal region includesgraphical and/or alphanumeric indicia.
 17. The ball bat of claim 10,wherein the outer layer includes one or more projections.
 18. The ballbat of claim 1, wherein the handle portion is a pultrusion.
 19. The ballbat of claim 10, wherein the element is a one-piece integral structurethat cannot be disassembled into component parts.
 20. The ball bat ofclaim 1, wherein an outer surface of the tapered proximal region of theelement is visible to a user.
 21. The ball bat of claim 1, wherein thebat is configured for organized, competitive play.
 22. The ball bat ofclaim 1, wherein the first texture is a first three-dimensional pattern.23. The ball bat of claim 22, wherein the second texture is a secondthree-dimensional pattern that is different from the first threedimensional pattern.